OK-

One casting is not bad but one is quite loose (rudder moves side to side in casting w/ rudder down.) I do not want to try and bend the casting as cast aluminum is pretty brittle. I have read up on prepping/aligning and shimming rudders, but with this unique frame, any advice on lining them to take up the slack? I know a more common rudder setup would be easier, but for now need to work with the stockers.

Thanks,

Jim.

Have you heard of Marine-Tex?
How about building up the rudder at one point so that it is tight in the frame when down? This would be a mound about the size of a quarter.

Oh yeah!
LOTS of Marine-Tex on these hulls and rudders to smooth out all the dings and rash. Good idea. Thanks! <img src="http://www.catsailor.com/forums/images/graemlins/cool.gif" alt="" />

You could also try small plastic ties on each side. Cheap, no waiting, no sanding.

Another good one!
Thanks.

tie wraps are the best for loose rudders!!

I'm not sure how it would work on a G cat but I used to mix up some of that epoxy stick stuff. and jam it in the bottom of the casting. Wrap the corrisponding part of the rudder with saran wrap and lock the rudder down, let it dry overnight. You can always knock the chunk back out if you want to make an adjustment, an re-do it. It worked really well on my Hobie 20, I haven't tried it on the N-20 but I probably should.

Like plumber's putty?

Not exactly. You can buy the epoxy sticks in Home Depot/Lowes or most hardware stores. I use the stuff for marine applications that is colored green on the outside and grey on the inside of the stick. You just cut off as much as you need and roll it out thin then fold in half and roll again. Repeat as many times as it takes to get a homogenous color. It dries off white and is excellent stuff to keep on hand for field repairs.

Chris.

zip ties seem like a good idea.
you can also contact cement formica to the head of the blade.

Thanks Flumpmaster that's the stuff I was talking about.